Chain conveyor

ABSTRACT

In some aspects, a conveyor chain includes a first link, a second link, and a coupler link coupled between the first link and the second link. The first link includes a first portion and a second portion, the second portion oriented parallel to and laterally spaced apart from the first portion. The first portion includes a first sprocket-engaging pin protruding laterally, and the second portion includes a second sprocket-engaging pin protruding laterally. The second link includes a first portion and a second portion. The first portion includes a first sprocket-engaging portion protruding laterally, and the second portion includes a second sprocket-engaging portion protruding laterally. A flight bar is positioned adjacent an end of the first sprocket-engaging portion of the first link.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of prior-filed, co-pending U.S.patent application Ser. No. 15/913,821, filed Mar. 6, 2018, which claimsthe benefit of U.S. Provisional Patent Application No. 62/467,761, filedMar. 6, 2017; U.S. Provisional Patent Application No. 62/467,766, filedMar. 6, 2017; U.S. Provisional Patent Application No. 62/467,767, filedMar. 6, 2017; U.S. Provisional Patent Application No. 62/467,769, filedMar. 6, 2017; U.S. Provisional Patent Application No. 62/467,770, filedMar. 6, 2017; and U.S. Provisional Patent Application No. 62/467,773,filed Mar. 6, 2017. The entire contents of each of these documents areincorporated by reference herein.

BACKGROUND

The present disclosure relates to material conveyors, and particularlyto chain and flight conveyors.

SUMMARY

Mining machines such as continuous miners and chain haulage units mayinclude chain conveyors that are capable of deflecting laterally inorder to travel through lateral turns. The chain conveyors may includeflight members for pushing or urging material along a pan. The chain maybe driven by one or more sprockets.

In one independent aspect, a conveyor chain includes a first link, asecond link, a coupler link, a first connecting pin, and a secondconnecting pin. The first link including a first portion and a secondportion, the second portion oriented parallel to and spaced apart fromthe first portion. The first portion includes a first sprocket-engagingportion protruding laterally away from the second portion. The secondportion includes a second sprocket-engaging portion protruding laterallyaway from the first portion. The second link includes a first portionand a second portion. The first portion includes a firstsprocket-engaging portion protruding laterally away from the secondportion of the second link. The second portion includes a secondsprocket-engaging portion protruding laterally away from the firstportion of the second link. The coupler link includes a first end and asecond end. The first connecting pin extends through the first end ofthe coupler link and extends between the first portion of the first linkand the second portion of the first link to removably couple the firstend to the first link. The first connecting pin is oriented parallel toand offset from the first sprocket-engaging portion and the secondsprocket engaging portion of the first link. The second connecting pinextends through the second end of the coupler link and extends betweenthe first portion of the second link and the second portion of thesecond link to removably couple the second end to the second link. Thesecond connecting pin is oriented parallel to and offset from the firstsprocket-engaging portion and the second sprocket engaging portion ofthe second link.

In another independent aspect, a link assembly for a conveyor chainincludes a first link and a flight. The link includes a first portionand a second portion, the second portion oriented parallel to and spacedapart from the first portion. The first portion includes a first outersurface facing away from the second portion and a firstsprocket-engaging pin protruding from the first outer surface. Thesecond portion includes a second outer surface facing away from thefirst portion and a second sprocket-engaging pin protruding from thesecond outer surface. The flight is positioned adjacent an end of thefirst sprocket-engaging pin and spaced apart from the first outersurface. The flight is removably coupled to the first sprocket-engagingpin.

In yet another independent aspect, a conveyor chain includes a firstlink, a second link, and a coupler link. The first link includes a firstportion and a second portion, the second portion oriented parallel toand laterally spaced apart from the first portion. The first portionincludes a first sprocket-engaging pin protruding laterally in adirection away from the second portion, and the second portion includesa second sprocket-engaging pin protruding laterally in a direction awayfrom the first portion. The first link defines a lateral plane extendinglaterally between the first sprocket-engaging pin and the secondsprocket-engaging pin. The lateral plane is oriented parallel to adirection of travel of the first link. The first link is symmetric aboutthe lateral plane. The second link includes a first portion and a secondportion, the second portion oriented parallel to and laterally spacedapart from the first portion. The first portion of the first linkincludes a first sprocket-engaging portion protruding laterally in adirection away from the second portion of the second link. The secondportion of the second link includes a second sprocket-engaging portionprotruding laterally in a direction away from the first portion of thesecond link. The second link is symmetric about the lateral plane. Thecoupler link includes a first end and a second end. The first end iscoupled to the first link and positioned between the first portion ofthe first link and the second portion of the first link. The second endis coupled to the second link and positioned between the first portionof the second link and the second portion of the second link. Thecoupler link is symmetric about the lateral plane.

In still another independent aspect, a link assembly for a conveyorchain includes a link having a first portion and a second portion, thesecond portion oriented parallel to and laterally spaced apart from thefirst portion. The first portion includes a first outer surface facingaway from the second portion and a first sprocket-engaging pinprotruding from the first outer surface. The second portion includes asecond outer surface facing away from the first portion and a secondsprocket-engaging pin protruding from the second outer surface. The linkdefines a lateral plane extending laterally between the firstsprocket-engaging pin and the second sprocket-engaging pin. The lateralplane is oriented parallel to a direction of travel of the link. Thelink is symmetric about the lateral plane.

In yet another independent aspect, a link assembly for a conveyor chainincludes a first link and a flight. The first link includes a firstportion and a second portion, the second portion oriented parallel toand spaced apart from the first portion. The first portion includes afirst outer surface facing away from the second portion and a firstsprocket-engaging pin protruding from the first outer surface. Thesecond portion includes a second outer surface facing away from thefirst portion and a second sprocket-engaging pin protruding from thesecond outer surface. The flight is positioned adjacent an end of thefirst sprocket-engaging pin and spaced apart from the first outersurface. The flight includes a scraper portion configured to engage aconveyor deck as the flight moves in a direction of travel. The scraperportion includes at least one base surface and a plurality of hardenedportions, the hardened portions having a hardness that is greater than ahardness of the base surface.

Other aspects will become apparent by consideration of the detaileddescription and accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a mining machine with a portion of agathering head cutaway.

FIG. 2 is a perspective view of a forward end of the mining machine ofFIG. 1.

FIG. 3 is an exploded view of a conveyor drive assembly.

FIG. 4 is a perspective view of a chain conveyor unit.

FIG. 5 is an exploded view of the chain conveyor unit of FIG. 4.

FIG. 6 is a perspective view of a flight link and a flight bar accordingto another embodiment.

FIG. 7 is a plan view of a surface of a flight bar according to anotherembodiment.

FIG. 8 is a perspective view of a chain conveyor unit according toanother embodiment.

FIG. 9 is an exploded view of the chain conveyor unit of FIG. 8.

Before any independent embodiments of the disclosure is explained indetail, it is to be understood that the disclosure is not limited in itsapplication to the details of the construction and the arrangements ofcomponents set forth in the following description or illustrated in thedrawings. The disclosure is capable of other independent embodiments andof being practiced or being carried out in various ways.

Also, it is to be understood that the phraseology and terminology usedherein is for the purpose of description and should not be regarded aslimiting. The use of “including,” “comprising” or “having” andvariations thereof herein is meant to encompass the items listedthereafter and equivalents thereof as well as additional items. Theterms “mounted,” “connected” and “coupled” are used broadly andencompass both direct and indirect mounting, connecting and coupling.Further, “connected” and “coupled” are not restricted to physical ormechanical connections or couplings, and can include electrical or fluidconnections or couplings, whether direct or indirect. Also, electroniccommunications and notifications may be performed using any known meansincluding direct connections, wireless connections, etc.

DETAILED DESCRIPTION

FIG. 1 illustrates a mining machine 10, such as a continuous miningmachine. In the illustrated embodiment, the mining machine 10 includes aframe or chassis 18, a boom 22 pivotably coupled to the chassis 18, anda cutter head 26 supported on the boom 22. The chassis 18 may besupported for movement relative to a support surface (not shown) by atraction mechanism (e.g., crawlers 30).

As shown in FIGS. 1 and 2, a collecting mechanism or gathering head 34is positioned adjacent a first end or forward end 38 of the chassis 18,and a conveyor 42 extends in a continuous loop from the forward end 38of the chassis 18 toward a second or rear end 46 of the chassis 18. Thegathering head 34 is positioned below the cutter head 26 and includes adeck 50 and a pair of rotating arms 54 that engage and direct dislodgedmaterial onto the conveyor 42. The conveyor 42 transports the cutmaterial from the forward end 38 toward the rear end 46 (FIG. 1) of thechassis 18, from the area below the cutter head 26 to another conveyoror a haulage machine (not shown) positioned proximate the rear end 46 ofthe chassis 18.

As shown in FIG. 2, the conveyor 42 is a chain conveyor formed by chainlink connected sequentially in a continuous loop. The conveyor 42 drivescut material along a chain pan or deck 58. The conveyor 42 is driven bya drive assembly including a shaft 62 positioned adjacent the gatheringhead 34 of the chassis 18. As shown in FIG. 3, the shaft 62 is orientedlaterally relative to the chassis 18 (FIG. 2) and is driven (e.g., byone or more motors) to rotate relative to the chassis 18. A pair ofsprockets 66 engage and move the conveyor 42. In the illustratedembodiment, each sprocket 66 includes four teeth or lobes 70 spacedapart about the shaft 62, and recesses between the lobes 70 receive anddrive the conveyor 42.

FIGS. 4 and 5 show a unit of the chain 82 that forms the conveyor 42. Inthe illustrated embodiment, the chain 82 includes a first link or flightlink 86, a second link or connecting link 90, a coupler link or swivellink 94 coupling the flight link 86 to the connecting link 90, andflights or flight bars 98 positioned laterally outward from the flightlink 86. Another swivel link 94 may couple the connecting link 90 toanother flight link (not shown), and the conveyor chain 82 may thereforeinclude a sequence of alternating flight links and connecting links,each joined to one another by swivel links. In other embodiments, thechain 82 may include a different sequence of links—for example, multipleconnecting links may be positioned between one flight link and thesubsequent flight link. Various permutations of the link sequence arepossible.

In the illustrated embodiment, the flight link 86 includes a pair oflugs or side portions 106 (a first side portion 106 a and a second sideportion 106 b) and a bridge 110 extending between inner surfaces of theside portions 106. Each side portion 106 includes a pair of apertures114 extending through the inner surface and an outer surface of eachside portion 106.

As best shown in FIG. 5, the flight link 86 further includes a pair offlight pins 122, and each flight pin 122 extends outwardly from theouter surface of one of the side portions 106. In the illustratedembodiment, the flight pins 122 are aligned with one another (i.e.,along a common axis), and each of the flight pins 122 is positionedbetween chain pins 222 (described in further detail below). Statedanother way, the flight pins 122 extend laterally or transverselyrelative to a direction of travel 126 of the conveyor 42. Each of theflight pins 122 is positioned between the apertures 114 of theassociated side portion 106. In the illustrated embodiment, each flightbar 98 is removably coupled to one of the flight pins 122 (e.g., by athreaded bolt 130 and nut 134). A sprocket-engaging portion or driveportion 138 of each flight pin 122 is positioned between the sideportion 106 and the associated flight bar 98. In the illustratedembodiment, an end portion 142 of each flight pin 122 is positionedwithin an opening 146 of one of the flight bars 98.

In addition, the flight pin 122 includes a pilot portion 150 positionedbetween the end portion 142 and the drive portion 138. The pilot portion150 is positioned between two lugs 154 of the flight bar 98. Sidesurfaces 158 of the pilot portion 150 contact and engage side surfacesof the flight bar lugs 154. The contact between the pilot portion 150and lugs 154 prevents rotation of the flight bar 98 about the flight pin122 and provides a reaction surface to reduce shear stress on the bolt130. In the illustrated embodiment, the pilot portion 150 has arectangular cross-section and the bolt 130 extends through the pilotportion; in other embodiments, the pilot portion may have a differentcross-section shape and/or the bolt 130 may extend through a differentportion of the flight pin 122. Also, in other embodiments (FIG. 6), theflight bar 98 may include only one lug 154.

As shown in FIG. 5, each connecting link 90 includes a pair of lugs orside portions 170 (a first side portion 170 a and a second side portion170 b) and a bridge 174 extending between inner surfaces of the sideportions 170. Each side portion 170 includes a pair of apertures 178extending through the inner surface and an outer surface of each sideportion 170. In addition, a drive pin 182 extends outwardly from anouter surface of each side portion 170. Stated another way, each drivepin 182 extends laterally or transversely relative to the direction oftravel 126 of the chain 82. Each drive pin 182 is positioned between theapertures 178 of the associated side portion 170. The sprockets 66 (FIG.3) engage the drive pins 182 and the drive portions 138 of the flightpins 122 to drive the chain 82. In the illustrated embodiment, thebridge 174 of the connecting link 90 includes an opening 186.

Referring now to FIG. 5, the swivel link 94 includes a first end 190, asecond end 194, and a pair of openings 198 extending laterally from oneside of the swivel link 94 to another, opposite side of the swivel link94. A swivel link longitudinal axis 200 extends between the first end190 and the second end 194. Under nominal operating conditions, theswivel link longitudinal axis 200 is aligned with the direction oftravel 126 of the chain 82. In the illustrated embodiment, the swivellink 94 is formed as a vertical open chain link in which the openings198 are separated by a gusset or reinforcement member 202. Thereinforcement member 202 extends between a first or upper wall 204 and asecond or lower wall 208 of the swivel link 94. Each swivel link 94further includes a pair of support members or bearings, such asspherical bearings 206. Each bearing 206 is positioned in a pocket 210(FIG. 5) formed in an associated one of the openings 198 of the swivellink 94.

One of the openings 198 is aligned with parallel apertures 178 in theside portions 170 of the connecting link 90, while the other opening 198is aligned with parallel apertures 114 in the side portions 106 of theflight link 86. A first connecting pin or first chain pin 214 isinserted through the apertures 178 of the connecting link side portions170 and through one opening 198 of the swivel link 94, thereby couplingthe swivel link 94 to the connecting link 90. Similarly, a secondconnecting pin or second chain pin 222 is inserted through the apertures114 of the flight link side portions 106 and through the other opening198 of the swivel link 94, thereby coupling the swivel link 94 to theflight link 86. Each of the chain pins 214, 222 is supported forpivoting movement relative to the swivel link 94 by one of the bearings206 positioned in the connected swivel link 94.

In addition, in the illustrated embodiment, the first chain pin 214 isinserted through the connecting link side portions 170 in a firstlateral direction, while the second chain pin 222 is inserted throughthe flight link side portions 106 in a second lateral direction oppositethe first lateral direction. The chain pins 214, 222 are secured againstmovement relative to the connecting link 90 and the flight link 86 byretainers (e.g., self-locking retaining rings—not shown). Also, in someembodiments, an outer side of one of the side portions 170 may includean aperture having a reduced diameter such that each pin 214 can only beinserted from one side of the connecting link to the other. Theapertures of the flight link may be structured in a similar manner.

The chain pins 214, 222 can be removed from the associated links withhand tools, at least partially because of the sliding fit connectionsbetween the pins 214, 222 and the links 86, 90, 94. As a result,individual components of the chain 82 may be easily disassembled,replaced, and re-assembled on-site, without requiring hot work (e.g.,cutting torches, welding tools, etc.). The chain 82 can be fullyrebuilt. Portions of the chain 82 may also be removed without requiringadditional parts (e.g., to re-connect the chain ends).

Similarly, the flight bars 98 are removably coupled to the flight pins122 rather than attached by welding. Unlike conventional conveyors, wornor damaged flight bars 98 can be easily replaced individually ratherthan replacing the entire flight section, thereby lowering maintenancecost of the chain 82.

The chain 82 is symmetric across a horizontal plane bisecting the chain82 into an upper portion and a lower portion. Stated another way, thechain 82 is symmetric from top to bottom. Unlike conventional chains,the chain 82 may be installed with either the upper or lower surfaceengaging the conveyor deck 58. In addition, after a period of use, thechain 82 may be inverted such that the upper portion of the chain 82 ispositioned adjacent the deck 58 and the chain 82 may be operated. Theinversion of the chain 82 may provide additional working life for thechain and reduce the frequency of replacement for chain components. Inaddition, the symmetric chain 82 avoids the need for dedicated scraperflights for return deck cleaning.

FIG. 7 illustrates another embodiment of the flight bar 498 includinglines or sections 556 of high hardness, low wear material positioned ona surface of the flight bar 498. In the illustrated embodiment, thesections are formed in lines extending at an angle relative to adirection of travel 126 of the flight bar 498 such that adjacentsections overlap one another relative to the direction of travel 126 (asillustrated by the dashed line between sections 556 in FIG. 7). Thelocalized hardening of portions of the flight bar 98 provides areas orregions having a lower wear rate than the base material of the flightbar 98. As the base material of the flight bar 98 wears, the hardenedareas remain and stand away from the base part creating a scraping edgefor removing material from the chain deck 58. The hardened sections 556may be positioned on both major surfaces of the flight bar 498.

FIGS. 8 and 9 illustrate a chain 882 according to another embodiment.Features of the chain 882 are similar to features of the chain 82 andare identified with similar reference numbers, plus 800. At least somedifferences and/or at least some similarities between the chain 82 and882 are described below. In addition, components or features describedwith respect to only one or some of the embodiments described herein areequally applicable to any other embodiments described herein.

The chain 882 includes a flight link 886 including a pair of sideportions 906 that are separate from one another and not directlyconnected. Stated another way, the flight link 886 does not include abridge between the side portions 906. Rather, the side portions 906 arecoupled to one another by the connecting pins 1022 (FIG. 9) extendingbetween the side portion 906 and through a swivel link 894. Similarly, aconnecting link 890 includes a pair of side portions 970 that areseparate from one another and not directly connected. Stated anotherway, the connecting link 886 does not include a bridge between the sideportions 970, which are formed as separate components 970 a, 970 b.Rather, the side portions 970 are coupled to one another by theconnecting pins 1014 (FIG. 9) extending between the side portion 970 andthrough the swivel link 894.

In addition, a flight 898 is formed integrally with each side portion906 of the flight link 886. In the illustrated embodiment, a driveportion 938 protrudes from each side portion 906, and the flight 898extends laterally outwardly from an end of the drive portion 938. Thedrive portion 938 is positioned between the side portion 906 and theflight 898. It is understood that aspects of the chain 882 may beincorporated into other disclosed embodiments. For example, an integralflight may be incorporated into the flight link 86 described above withrespect to FIGS. 4 and 5.

Although the conveyor is described above with respect to a continuousmining machine, it is understood that the conveyor may be incorporatedinto other types of machines including but not limited to roadheadersand entry drivers, as well as loading and hauling machines including butnot limited to shuttle cars, battery haulers, or other types.

Although aspects have been described in detail with reference to certainpreferred embodiments, variations and modifications exist within thescope and spirit of one or more independent aspects as described.

What is claimed is:
 1. A link assembly for a conveyor chain, the linkassembly comprising: a link including a first portion and a secondportion, the second portion oriented parallel to and spaced apart fromthe first portion, the first portion including a first outer surfacefacing away from the second portion and a pin protruding from the firstouter surface; and a flight including a body and a single lug extendingfrom the body, the lug positioned adjacent one side of the pin, the bodyextending in a direction away from an end of the pin, the lug coupled tothe pin to removably couple the flight to the pin.
 2. The link assemblyof claim 1, wherein a fastener extends between the pin and the lug tocouple the lug to the pin.
 3. The link assembly of claim 2, wherein thefastener includes a bolt having a head engaging one of an outer surfaceof the lug and an outer surface of the pin, further including a nutthreadably engaging the bolt and engaging the other of the outer surfaceof the lug and the outer surface of the pin.
 4. The link assembly ofclaim 1, wherein the flight is a first flight, and wherein the secondportion includes a second outer surface facing away from the firstportion and a second pin protruding from the second outer surface, thelink assembly further comprising, a second flight including a body and asingle lug extending from the body of the second flight, the lugpositioned adjacent one side of the second pin, the body extending in adirection away from an end of the second pin, the lug coupled to thesecond pin to removably couple the second flight to the second pin. 5.The link assembly of claim 1, wherein the first portion of the link andthe second portion of the link are integral with one another.
 6. Thelink assembly of claim 1, wherein the flight includes a first part madefrom a first material and a second part made from a second materialhaving a higher hardness than the first material.
 7. The link assemblyof claim 6, wherein the second part includes an edge oriented at anoblique angle relative to the direction of travel.
 8. The link assemblyof claim 1, wherein the pin includes a sprocket-engaging portion, andwherein the pin and the sprocket-engaging portion are in alignmentrelative to the first portion of the link.
 9. A link assembly for aconveyor chain, the link assembly comprising: a link including a firstportion and a second portion, the second portion oriented parallel toand spaced apart from the first portion, the first portion including afirst outer surface facing away from the second portion and a firstsprocket-engaging portion protruding from the first outer surface, thesecond portion including a second outer surface facing away from thefirst portion; and a flight positioned adjacent an end of the firstsprocket-engaging portion, the flight including a first part made from afirst material and a second part made from a second material having ahigher hardness than the first material; wherein as the first part wearsduring normal use, the second part protrudes beyond a surface of thefirst part and provides a scraping edge.
 10. The link assembly of claim9, wherein the second part includes an edge oriented at an oblique anglerelative to a direction of travel of the flight.
 11. The link assemblyof claim 9, wherein the second part is one of a plurality of secondparts, and wherein the plurality of second parts are spaced apart fromone another along a length of the flight.
 12. The link assembly of claim11, wherein the each of the plurality of second parts are oriented atoblique angle relative to a direction of travel of the flight, each ofthe second parts overlapping with an adjacent one of the second partsrelative to the direction of travel of the flight.
 13. The link assemblyof claim 9, wherein the flight is a first flight, wherein the secondportion includes a second sprocket-engaging portion protruding from thesecond outer surface, the link assembly further comprising, a secondflight positioned adjacent an end of the second sprocket-engagingportion, the second flight including a first part made from a firstmaterial and a second part made from a second material having a higherhardness than the first material.
 14. The link assembly of claim 9,wherein the first portion of the link and the second portion of the linkare integral with one another.
 15. The link assembly of claim 9, whereinthe flight is removably coupled adjacent the end of the firstsprocket-engaging portion by a fastener.
 16. A conveyor chaincomprising: a first link including a first portion and a second portion,the second portion oriented parallel to and spaced apart from the firstportion, the first portion including a first sprocket-engaging portionprotruding laterally away from the second portion, the second portionincluding a second sprocket-engaging portion protruding laterally awayfrom the first portion; a second link including a first portion and asecond portion, the first portion of the second link including a firstsprocket-engaging portion protruding laterally away from the secondportion of the second link, the second portion of the second linkincluding a second sprocket-engaging portion protruding laterally awayfrom the first portion of the second link; a coupler link including afirst end and a second end; a first connecting pin extending through thefirst end of the coupler link, the first connecting pin extendingbetween the first portion of the first link and the second portion ofthe first link to removably couple the first end of the coupler link tothe first link, the first connecting pin oriented parallel to and offsetfrom the first sprocket-engaging portion and the secondsprocket-engaging portion of the first link; a second connecting pinextending through the second end of the coupler link, the secondconnecting pin extending between the first portion of the second linkand the second portion of the second link to removably couple the secondend of the coupler link to the second link, the second connecting pinoriented parallel to and offset from the first sprocket-engaging portionand the second sprocket-engaging portion of the second link; and a firstflight positioned adjacent an end of the first sprocket-engaging portionof the first link, the flight including a first part made from a firstmaterial and a second part made from a second material having a higherhardness than the first material.
 17. The conveyor chain of claim 16,wherein the second part includes an edge oriented at an oblique anglerelative to a direction of travel of the flight.
 18. The conveyor chainof claim 16, wherein the second part is one of a plurality of secondparts, and wherein the plurality of second parts are spaced apart fromone another along a length of the flight, each of the plurality ofsecond parts oriented at an oblique angle relative to a direction oftravel of the flight, each of the second parts overlapping with anadjacent one of the second parts relative to the direction of travel ofthe flight.
 19. The conveyor chain of claim 16, further comprising asecond flight positioned adjacent an end of the second sprocket-engagingportion of the second link, the second flight including a first partmade from a first material and a second part made from a second materialhaving a higher hardness than the first material.
 20. The conveyor chainof claim 19, wherein the first flight is removably coupled adjacent theend of the first sprocket-engaging portion by a first fastener, andwherein the second flight is removably coupled adjacent the end of thesecond sprocket-engaging portion by a second fastener.